Xerox DFC155 Troubleshooting guide

DFC155 & DWC155c Service Manual & Spare Parts Catalogue
602E52970Important Note
This is a first edition of the Service Manual and Spare Parts Catalogue.
To read the manual Adobe Acrobat 3.0 is needed as the .pdf files are not 2.1 compatible.
In the contents section there is a reference to remote diagnostics in chapter 5.
The section on this has been removed, as remote diagnostics are not legal in all countries.
Additionally a master unit is required. This master unit is no longer sold.
There are no references to the Linkfax softswitches in section 4 (DWC155c only). These will
be included in the next revision of the manual.

DFC155
DWC155c
SERVICE MANUAL
Part Number 602E52970

PUBLICATION ISSUED BY:
Xerox Limited Technical Centre
Bessemer Road
Welwyn garden City
Herts AL7 1HE
United Kingdom
WARNING
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type
recommended by the manufacturer.
Dispose of used batteries according to the manufacturer's instructions.

PREFACE
This manual, intended for service engineers responsible for installing, servicing and
repairing the facsimile machines described herein, consists of eight chapters covering:
•Chapter 1: the General Features and Technical Specifications
•Chapter 2: the facsimile machine's Internal and external structure
•Chapter 3: the Installation and setup procedures
•Chapter 4: how to set the Software Parameters
•Chapter 5: the Diagnostic and testing procedures
•Chapter 6: the Settings and adjustments
•Chapter 7: the Maintenance and replacement procedures
•Chapter 8: the Optional devices
DISTRIBUTION: General (G)
FIRST EDITION: January 1998
REFERENCES:User Manual
Spare parts catalogue

602E52970 v
CONTENTS
1. INTRODUCTION .......................................................... 1-1
1.1 MAIN FEATURES .......................................................................... 1-1
1.2 TECHNICAL SPECIFICATIONS ................................................... 1-2
1.3 QUICK REFERENCE GUIDE ........................................................ 1-5
1.3.1 Sending a Fax............................................................................................... 1-5
1.3.2 Receiving a Fax ............................................................................................ 1-5
1.3.3 Using the Facsimile Machine as a Photocopier ........................................... 1-5
2. GENERAL DESCRIPTION ........................................... 2-1
2.1 EXTERNAL PARTS ....................................................................... 2-1
2.1.1 Console ........................................................................................................ 2-2
2.1.2 Functions of the console keys ...................................................................... 2-3
2.2 ELECTROMECHANICAL PARTS ................................................. 2-6
2.2.1 Motors, elctromagnet and loudspeaker ....................................................... 2-6
2.2.2 Sensors ........................................................................................................ 2-7
2.3 ELECTRONIC PARTS ................................................................... 2-8
2.3.1 General Block Diagram ................................................................................ 2-9
2.3.2 Block Diagram of the Motherboard ............................................................ 2-10
2.3.3 Block Diagram of the Network Control Unit Board..................................... 2-13
2.3.4 Block Diagram of the Power Supply Board ................................................ 2-14
2.3.5 Printer Unit ................................................................................................. 2-16
2.3.6 Paper Feeding ............................................................................................ 2-18
3. INSTALLATION AND INITIALIZATION
PROCEDURES ............................................................ 3-1
3.1 PRELIMINARY OPERATIONS ...................................................... 3-1
3.1.1 Unpacking the Facsimile Machine ................................................................ 3-1
3.1.2 Connecting the Power Cord ......................................................................... 3-2
3.1.3 Inserting the paper support extension ......................................................... 3-2
3.1.4 Paper Supply ................................................................................................ 3-2
3.1.5 Installing the Print Head ............................................................................... 3-3
3.1.6 Connecting to the Telephone Line ................................................................ 3-8
3.1.7 Connecting the Handset ............................................................................... 3-9

vi 602E52970
3.2 INSTALLING AND SETTING UP THE MACHINE ........................3-10
3.2.1 Organization of the Installation and Setup Parameters ............................. 3-10
3.2.2 Setting the Country Parameters................................................................. 3-13
3.2.3 Storing the User's Number and Name ....................................................... 3-14
3.2.4 Setting Up the Telephone Line ................................................................... 3-15
3.2.5 Completing Installation ............................................................................... 3-17
3.2.6 Resetting the Fax Machine......................................................................... 3-19
4. SERVICE SWITCHES .................................................. 4-1
4.1 SERVICE SWITCH TABLES .......................................................... 4-3
5. DIAGNOSTICS ............................................................. 5-1
5.1 SELF-DIAGNOSTICS .................................................................... 5-1
5.1.1 Description of the Self-Diagnostic Program ................................................. 5-2
5.2 ERROR CODES ............................................................................ 5-3
5.2.1 Meaning of Protocol Signal Codes ............................................................... 5-4
5.2.2 Meaning of Error Codes ............................................................................... 5-6
5.2.3 Printing the Communication Protocol ........................................................... 5-9
5.3 REPORTS .................................................................................... 5-11
5.3.1 Transmission Report (LAST TX REPORT) ................................................ 5-11
5.3.2 Journal (ACTIVITY REPORT) .................................................................... 5-13
5.3.4 Loss of Mains Power Supply Report .......................................................... 5-13
5.4 REMOTE DIAGNOSTICS .............................................................5-15
5.4.1 Enabling the Facsimile Machine as a "Slave Station" ................................ 5-15
6. SYSTEM TEST AND ADJUSTMENTS ......................... 6-1
6.1 SYSTEM TEST .............................................................................. 6-1
6.1.1 ALIGNMENT TEST ...................................................................................... 6-2
6.1.2 NOZZLES TEST ........................................................................................... 6-4
6.1.3 PRINT CHART .............................................................................................. 6-5
6.1.4 ASF TEST ..................................................................................................... 6-8
6.1.5 ADF TEST .................................................................................................... 6-8
6.1.6 LOAD DEFAULT ........................................................................................... 6-9
6.1.7 SCANNER SHADING ................................................................................... 6-9
6.1.8 CARRIAGE TEST ....................................................................................... 6-10

602E52970 vii
6.2 CHECKS AND ADJUSTMENTS .................................................. 6-11
6.2.1 Checking the Direct Voltages ..................................................................... 6-11
7. MAINTENANCE AND REPLACEMENT
PROCEDURES ............................................................ 7-1
7.1 MAINTENANCE ............................................................................ 7-1
7.1.1 OUT OF INK Message ................................................................................. 7-1
7.1.2 Replacing the rechargeable Ink Cartridge ................................................... 7-2
7.1.3 Replacing the Print Head ............................................................................. 7-2
7.1.4 Cleaning the Print Head ............................................................................... 7-2
7.1.5 Cleaning the Electrical Contacts .................................................................. 7-3
7.1.6 Cleaning the Print Head Cleaning Pad ........................................................ 7-4
7.1.7 Cleaning the Optical Unit ............................................................................. 7-5
7.2 DISASSEMBLY AND REPLACEMENT PROCEDURES ............... 7-6
7.2.1 Wirings .......................................................................................................... 7-6
7.2.2 Removing the Casing ................................................................................... 7-8
7.2.3 Disassembling the base ............................................................................... 7-9
7.2.4 Replacing the motherboard and the NCU Board ....................................... 7-11
7.2.5 Replacing System Software ....................................................................... 7-13
7.2.6 Replacing the Power Supply Board ............................................................ 7-13
7.2.7 Replacing the Loudspeaker ........................................................................ 7-15
7.2.8 Replacing the Print Head Cleaner Electromagnet ..................................... 7-15
7.2.9 Replacing the Scanning/Interline Motor ..................................................... 7-16
7.2.10 Replacing the Carriage Motor .................................................................... 7-21
7.2.11 Replacing the Print Head Pad .................................................................... 7-22
7.2.12 Replacing the Carriage............................................................................... 7-22
7.2.13 Replacing the Forward Driving Rollers ....................................................... 7-25
7.2.14 Replacing Paper Shifter Rollers ................................................................. 7-26
7.2.15 Replacing Rear Driver Rollers .................................................................... 7-26
7.2.16 Replacing the Optical Unit (CIS) ................................................................ 7-29
7.2.17 Replacing the Document Sensor ............................................................... 7-29
7.2.18 Replacing the Paper Sensor ...................................................................... 7-30
7.2.19 Replacing the Console Board .................................................................... 7-31
7.2.20 Replacing the Display ................................................................................. 7-32
7.2.21 Restoring the Facsimile Machine ............................................................... 7-33
8. OPTIONAL DEVICES .................................................. 8-1
8.1 SETTING UP A BACK TO BACK CONNECTION .......................... 8-2
8.2 CONNECTING A TELEPHONE ANSWERING DEVICE OR AN
EMERGENCY PHONE SET .......................................................... 8-2

1-1602E52970
1. INTRODUCTION
This device is a desktop fax machine with inkjet printing, complying with the ITU-TS
G3 standard for the transmission and reception of documents.
1.1 MAIN FEATURES
•Bubble ink jet printing
Allows the use of normal paper with individual sheets of A4, Letter and Legal
format.
•Memory capacity
The fax machine has a memory which enables operations such as One-touch
Dialling, Speed Code Dialling and Substitute Reception, as well as the storage
of parameters, data and documents. This memory is powered by a backup battery
in the event of a power failure.
•Half tones
In the scanning of documents, a scale of 64 half tones can be used for a higher
quality reproduction of photographs and pictures.
•Automatic Document Feeder (ADF)
The fax machine allows automatic feeding of up to 5 documents in A4, Letter or
Legal format, with a maximum thickness of 0.1 mm/sheet.

1-2 602E52970
(1) with the document output tray >>
Desktop transceiver
359 x 264 (+ 841) x 193 (+ 1381) mm
5 kg
2 lines of 16 characters
- 15 function keys of which 4 are dual function and
two are triple function
- 12 dual-function keys for normal dialling and user
name setting
- 10 one-touch dialling keys
- 1 light indicator
220-240V, 50/60Hz
6W (in standby); max 30W
Public telephone network (PSTN) or private branch
exchange (PBX)
ITU-TS G3 standard
CCITT V29 / V27ter
2400 / 4800 / 7200 / 9600 bps
Half duplex
MH, MR (DFC 155)
MH, MR, MMR (DWC155c)
About 15 s for ITU-TS test sheet n°1 (Slerexe Letter)
at 9600 bps in standard resolution
•Telephone answering device (TAD)
The model without a built-an TAD can be connected to an external one.
1.2 TECHNICAL SPECIFICATIONS
Physical characteristics
Type
Dimensions (L, D, H)
Weight
Operator console
Display
Keypad
Power supply
Operating range
Absorption
Communication characteristics
Type of connection
Compatibility
Type of modulation
Transmission speed
Type of communication
Coding methods
Transmission time

1-3602E52970
>>
Contact Sensor (CIS)
Vertical: 3.85 (standard) / 7.7 (fine) lines/mm
Horizontal: 8 dots/mm
From 210 x 148 mm (minimum length) to 216 x 600 mm
(maximum length)
Horizontal: 216 mm
Vertical: within 2 mm of the edge of the document
Capacity: 5 sheets of A4 / US Letter / Legal format
(max thickness 0.1 mm/sheet)
Sheet thickness: min 0.06 mm, max 0.12 mm
The facsimile machine can emphasize the contrast of text
areas and reproduce pictures with 64 half tones.
Three levels are handled: dark, normal and light
Bubble ink jet on plain paper
ITU-TS test sheet n°1 (Slerexe Letter) / about 40 s
Capacity: 40 sheets of A4 / US Letter/ Legal format
(weight 70-90g/m2)
300 x 300 dpi
208 x 290 (A4) / 273 (Letter US) / 349 (Legal) mm
512 kbytes, of which about 450 available to the user,
powered by a backup battery
Pulse and tone
The number can be dialled directly on the facsimile
machine's keypad
Scanner
Scanning system
Resolution
Document size (width x length)
Actual scanning area
Automatic document feeder
(ADF)
Half tones
Contrast
Printer
Printing method
Printing speed
Automatic sheet feeder
Print resolution
Actual printing area
Memory
Capacity
Dialling
Dialling mode
Dialling on facsimile machine

1-4 602E52970
Redialling
One-touch dialling
Speed code dialling
Other features
Automatic reception
Polling
Reports
Environmental condi-
tions
Temperature
Relative humidity
A number can be redialled in automatic or manual mode
10 numerical keys (0 ÷ 9) are available
32 memory locations are available, and each may be as-
signed a facsimile or telephone number ID
The facsimile machine can be set to receive a document
automatically
Polling is available both for transmission and reception
Various kinds of reports may be printed (transmission,
activity, etc.)
Operating: from 5°C to 35°C
Storage:from 0°C to +45°C
Transport:from -15°C to +45°C
Operating: from 15% to 85 % (without condensation)
Storage: from 15% to 85 % (without condensation)
Transport: from 5% to 95 % (without condensation)

1-5602E52970
1.3 QUICK REFERENCE GUIDE
1.3.1 Sending a Fax
1. Insert the document into the automatic document
feeder.
2. Press the HOOK key and dial the correspondent's
number on the numeric keypad.
1.3.2 Receiving a Fax
1. The facsimile machine is normally set for automatic
reception: the message AUTOMATIC RX is dis-
played.
2. If you want to receive a fax in manual mode, press
the RX MODE key: the message MANUAL RX will
be displayed.
1.3.3 Using the Facsimile Machine as a Photocopier
1. Insert the document (max 5 sheets) into the auto-
matic document feeder
2. Type on the numeric keypad the number of copies
to make (max. 9 copies)
3. If necessary, set contrast (C), resolution (R) and
enlargement or reduction rate (I)
4. Press the COPY key.
n
Õ
Ó
Ò
Õ
Ð
Ð
Ð
,
5
&

602E52970 2-1
2. GENERAL DESCRIPTION
2.1 EXTERNAL PARTS
The figure shows the main external parts, of the facsimile machine.
1. Handset 8. Display
2. Paper support extension 9. Outlet for original documents and
documents received or copied
3. Automatic sheet feeder (ASF)
10. Loudspeaker
4. Paper format adjustment lever
11. Connection sockets
5. Automatic document feeder (ADF) 12. Printer lid
6. Document guides 13. Print carriage
7. Console 14. Optical reader
Fig. 2-1 External parts of the facsimile machine

2-2 602E52970
2.1.1 Console
Fig. 2-2 Console layout
The console comprises:
•a display consisting of 2 lines of 16 characters each
•a keypad consisting of:
- 15 function keys ( - - -COPY - STOP - HOOK - START - F- RX/STANDBY
MODE - RESOL. - CONTR. - S. DIAL/CLEAR - LAST TX/REDIAL - EXT./
PAUSE - R) of which 4 are dual function keys (RX/STANDBY MODE - S.DIAL/
CLEAR - LAST TX/REDIAL - EXT./PAUSE) and two are triple function keys
(RESOL. / / - CONTR.// )
- 12 triple-function keys: for normal dialling (0 - 1 - 2- 3- 4- 5 - 6 - 7 - 8 - 9 - *
- #), for user name setting (ABD - DEF - GHI - JKL - MNO - PQRS - TUV -
WXYZ - I→T - &...), for one-touch dialling (0 - 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9)
or, in pairs, for speed dialling
- 1 LED for indicating ERROR conditions.

602E52970 2-3
2.1.2 Functions of the Console Keys
Some keys perform different functions according to the current operating mode of the
facsimile machine:
Stand-by mode with document on the ADF
Stand-by mode without document on the ADF
Function mode (activated by pressing the FUNCTION key), irrespective of
the presence of a document on the ADF
Hook mode (activated by pressing the Hook key or lifting the handset).
Key Mode Functions
 Used for dialling numbers.
Number keys Select alphanumeric characters for setting the users name.
P→T In pulse dialling mode, changes the dialling mode to tone.
In tone dialling mode, emits a tone on line for special network
services.
« In tone dialling mode, emits a tone on line for special network
services.
«Scrolls forward through the special characters and sym-
bols for the users name; selects the +character for the users
telephone number; used to dial remote control codes.
# In tone dialling mode, emits a tone on line for special network
services.
&... Scrolls backwards through the special characters and
symbols available for the mnemonic ID.
F Provides access to operator selection menus and
submenus.
RX MODE  Changes the reception mode: automatic, manual, FAX/
TEL, FAX/TAD.
HOLD During a telephone conversation, puts the call on hold.
RESOL. Selects the type of resolution of the document to be trans-
mitted.
Moves the cursor left during entry of the user's name and
number.
Reduces the volume of the speaker.
>>

2-4 602E52970
Key Mode Functions
CONTR. Selects the type of contrast of the document to be transmit-
ted.
Moves the cursor right during entry of the user's name and
number.
 Increases the volume of the speaker.
S. DIAL  Enables the setting of a two-digit code for speed dialling.
CLEAR  Clears wrong settings.
LAST TX  Pressed once, displays the result of the last transmission.
REDIAL  Pressed twice, redials the last number.
EXT. When the facsimile machine is connected to a private branch
exchange, enables access to the public line.
PAUSE  Inserts a pause in dialling the number of the called party.
REnables to access the special functions made available by the
network operator and commonly known as REGISTER RE-
CALL.
Switches off the ERROR LED.
Stops copying, sending or receiving a document.
STOP Sets the facsimile machine in standby mode.
HOOK  Enables the user to dial the number without lifting the
receiver and to monitor the tones through the speaker.
Starts manual reception (with the handset lifted)
 After the number has been dialled, starts sending the
document on the ADF.
START After the handset is lifted, it places the facsimile in manual
reception mode.
Confirms menus, submenus, parameters and values.
Sets the facsimile in manual reception mode.
>>

602E52970 2-5
Key Mode Functions
Selects the enlargement (140%) or the reduction (70%) of
the document to be copied.
Selects the type of resolution of the document to be copied.
Selects the type of contrast of the document to be copied.
COPY Starts copying the document inserted in ADF.

2-6 602E52970
2.2 ELECTROMECHANICAL PARTS
2.2.1 Motors, Electromagnet and Loudspeaker
Behind the front side
Loudspeaker
Carriage motor
Rear left-hand side
Paper and
scanner motor
Fig. 2-3 Locating the motors
Underneath the scanning plane
Fig. 2-4 Locating the Head clearing E.M.
Head clearing
E.M.

602E52970 2-7
2.2.2 Sensors
console
sensor
(under the
console)
receiver
sensor
(under the
console)
Fig. 2-5 Locating the paper and printer sensors
Fig. 2-6 Locating the carriage sensor
paper edge
sensor
Fig. 2-7 Locating the paper sensors
document
sensor (under
the ADF plane)
paper sensor
(under scanning
plane)

2-8 602E52970
2.3 ELECTRONIC PARTS
Figure 2-8 shows the boards assembled on the facsimile machine.
Fig. 2-8 Locating the boards
1. Contact Sensor (CIS)
2. Power supply board
3. Motherboard
4. Network Control Unit board
1
2
3
4